Light-weight composition and mix for masonry, mortar and stucco

ABSTRACT

A pre-mixed mortar, stucco or masonry composition includes from 70 to 80 percent sand and from 20 to 30 percent of a light-weight cement mix composition. The light-weight cement mix composition comprises either slag cement, gypsum or a combination of slag cement and gypsum; Portland cement; silicon dioxide; calcium stearate; and metakaolin.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation-in-part of U.S. patent applicationSer. No. 14/100,728, filed Dec. 9, 2013; which is a continuation-in-partof U.S. patent application Ser. No. 13/832,753, filed Mar. 15, 2013 nowU.S. Pat. No. 8,623,133; which is a continuation-in-part of U.S. patentapplication Ser. No. 13/563,902, filed Aug. 1, 2012 now U.S. Pat. No.8,419,852; which is a continuation-in-part of U.S. patent applicationSer. No. 13/330,763, filed Dec. 20, 2011, now U.S. Pat. No. 8,252,108which is a continuation-in-part of U.S. patent application Ser. No.13/168,412, filed Jun. 24, 2011, now U.S. Pat. No. 8,101,017 which is acontinuation-in-part of U.S. patent application Ser. No. 12/945,941,filed Nov. 15, 2010, now U.S. Pat. No. 7,967,908.

This application is related to U.S. Pat. No. 7,468,102 titled,“LIGHT-WEIGHT COMPOSITION FOR MASONRY, MORTAR AND STUCCO,” inventorJorge G. Chiappo.

FIELD OF THE INVENTION

This invention relates to the field of cement and more particularly to alight-weigh composition of pre-mixed cement mix and sand.

BACKGROUND OF THE INVENTION

Mortar and stucco normally consists of the combination of cement andsand in a ratio of approximately three (3) parts sand to one (1) partcement. Directions for specific brands of cement usually call for from2.25:1 to 3:1 sand to cement ratios. The cement is generally mixed atthe job-site in a gasoline or electric powered mortar mixers. Often, thesand is delivered in bulk, while the cement mix is delivered in bagsweighing either 78 or 80 pounds. Due to the weight of the bags, they areoften delivered on palates and lifted with fork lifts and/or cranes. Onebag of cement mix is mixed with approximately three cubic feet of sand.Water is added to achieve a consistency that allows good workability.While the term sand is used throughout this disclosure for ease ofdiscussion, those skilled in the art will recognize that sand mayinclude other heavy aggregates, such as gravel, crushed stone and thelike.

Pre-mixed mortar, stucco or masonry mix is a form of concrete that ispre-mixed at the manufacturing site and typically delivered to the jobsite in packages such as bags. The package (e.g. bag) contains a mixtureof sand and concrete and, optionally, other aggregates. Typically, thepre-mixed mortar, stucco or masonry is used by adding water and applyingto the job site.

The weight and volume of these bags of pre-mix mortar, stucco or masonrycreate several problems. During storage, the weight and volume relate tothe total storage space required and the cost of transporting within thewarehouse. During transportation, the volume and weight affect the totalnumber of bags that fit within a given truck and the fuel consumptionrequired to transport the bags to the construction site. At theconstruction site, the weight becomes more of an issue since individualbags are often lifted by a worker and many bags are lifted per day, the78-80 pound bags cause fatigue and are the cause of many stress-relatedailments. For home use, smaller bags (e.g. 60 pound bags) are often soldsince many homeowners find it difficult to lift 80 pounds.

U.S. Pat. No. 5,718,758 to Breslauer recognizes that mortars of theprior art create problems due to weight, leading to worker injury duringcarrying of the mortar, etc.

Other cement compositions disclosed in U.S. Pat. No. 6,840,996 toMorioka, et al, U.S. Pat. No. 7,070,647 to Fujimori, et al, and U.S.Pat. No. 7,148,270 to Bowe describe various cement compositions, none ofwhich provide a light-weight ready-mix composition.

U.S. Pat. No. 7,468,102 to Jorge G. Chiappo describes a light-weightcement mix, but not a pre-mixed composition comprising sand.

Existing pre-mixed compositions have a substantial effect on theenvironment. For example, in Florida alone, around 25 million bags ofpre-mix were consumed in 2008, or approximately 1 million tons ofmaterial that had to be mined, shipped, hauled and used. By reducing theper-bag weight by 18 percent while producing an equivalent yield 820million tons of material would be mined, shipped, hauled and used tocreate the same amount of finished product that previously contributedto 1 million tons of material that had to be mined, shipped, hauled andused. That means, 180M tons less in raw materials mined, significantlyless transportation costs, less wear and tear on vehicles, less fossilfuel used in transportation, less structure for storage, reducedpersonal injury from strain, etc.

What is needed is a light-weight, pre-mixed mortar, stucco or masonrymix ready for adding water at the job site.

SUMMARY OF THE INVENTION

In one embodiment, a pre-mixed mortar, stucco or masonry composition isdisclosed including from 70 to 80 percent sand and from 20 to 30 percentof a light-weight cement mix composition that comprises either slagcement, Gypsum or a combination of slag cement and gypsum; Portlandcement; silicon dioxide; calcium stearate; and metakaolin.

In another embodiment, a pre-mixed mortar, stucco or masonry compositionis disclosed comprising approximately 75 percent sand and approximately25 percent of a light-weight cement mix composition that includes from 1to 10 percent silicon dioxide; 0.5 to 2 percent calcium stearate; 1 to10 percent metakaolin; up to 20 percent slag cement; and from 60 to 91percent Portland cement.

In another embodiment, a pre-mixed mortar, stucco or masonry compositionis disclosed comprising approximately 75 percent sand and approximately25 percent of a light-weight cement mix composition that includes from 1to 10 percent silicon dioxide by weight; 0.5 (½) to 1 percent calciumstearate by weight; 1 to 10 percent metakaolin by weight; up to 20percent slag cement by weight; and up to 91 percent Portland cement byweight.

The invention can be best understood by those having ordinary skill inthe art by reference to the following detailed description.

DETAILED DESCRIPTION OF THE INVENTION

Reference will now be made in detail to the presently preferredembodiments of the invention. Although the disclosed pre-mixed mortar,stucco or masonry mixture is ideal for use in masonry, mortar andstucco, there is no limitation to the application of the mortar, stuccoor masonry mix of the present invention.

Prior to the present invention, pre-mixed mortar, stucco or masonry mixis typically delivered to the job site in bags weighing 78 or 80 pounds.The weight of these bags often causes stress and strain injuries to theworkers. Additionally, transporting and storage of these bags utilizesmore space and energy than is needed. The pre-mixed cement of thepresent invention provides the same resulting volume of cement with thestrength and consistency of the prior art cement mixtures at a per-bagweight of approximately 65 pounds, saving energy and storage space andreducing worker stress and strain. Although 65 pound bags are used as anexample, it is known and anticipated to produce the claimed product inany size bag or container including an 80 pound bag that will produce agreater resulting volume than an 80 pound bag of the prior art cementmixtures.

The mortar, stucco or masonry mix of the present invention is mixed withwater as the prior mortar, stucco or masonry mixes. Mixing a 65 poundcontainer of the pre-mixed cement mix of the present invention withwater, results in a volume is similar to that of an 80 pound containerof a pre-mixed cement mix of the prior art. Therefore, a 65 pound bag ofthe mortar, stucco or masonry mix of the present invention produces asimilar amount (volume) of mortar, stucco or masonry when mixed withwater as did an 80 pound bag of the prior art.

In some embodiments, the pre-mixed mortar, stucco or masonry mix of thepresent invention consists of approximately 75% sand and a light-weightcement mix composition of from 35% to 90% cement by weight (either slagcement, Portland cement or hydraulic cement), from 2% to 10% fly ash orhydrous magnesium sulfate by weight, from 1% to 3% sodium tall oil(e.g., a wood pulp by-product) by weight, from 1% to 2% sodium stearateby weight, from 1% to 2% sodium C₁₄-₁₆ Alpha Olefin by weight, from 1%to 3% linear alkyl benzene by weight and from 10% to 20% silicon dioxideSiO₂ (also known as silica or silox) or fly ash by weight. Silicondioxide SiO₂ is often derived from fly ash which is a byproduct of coalcombustion. Fly ash also consists of aluminum oxide (Al₂O₃) and ironoxide (Fe₂O₃).

In some embodiments, the pre-mixed mortar, stucco or masonry mix of thepresent invention consists of approximately 75% sand and a light-weightcement mix composition of from 35% to 90% of either slag cement,Portland Cement and/or Gypsum, from 2% to 10% ground granulated blastfurnace slag (GGBFS) by weight, from 1% to 3% sodium tall oil (e.g., awood pulp by-product) by weight, from 1% to 2% sodium stearate byweight, from 1% to 2% sodium C₁₄-₁₆ Alpha Olefin by weight, from 1% to3% linear alkyl benzene by weight and from 10% to 20% silicon dioxideSiO₂ (also known as silica or silox) by weight. Silicon dioxide SiO₂ isoften derived from fly ash which is a byproduct of coal combustion. Flyash also consists of aluminum oxide (Al₂O₃) and iron oxide (Fe₂O₃).

In some embodiments, the pre-mixed mortar, stucco or masonry mix of thepresent invention consists of approximately 75% sand and a light-weightcement mix composition of from 60% to 91% of Portland Cement by weight,from zero to 20% Slag Cement by weight, from 4% to 20% ground plastic,preferably polystyrene by weight, from 0% to 20% Perlite or Mica byweight, and from 5% to 10% clay by weight.

In some embodiments, the pre-mixed mortar, stucco or masonry mix of thepresent invention consists of approximately 75% sand and a light-weightcement mix composition of up to 91% of Portland Cement, preferably from60% to 91% of Portland Cement by weight, from zero to 20% Slag Cement byweight, from 1% to 10% silicon dioxide by weight, from 1% to 2% calciumstearate, and from 1% to 10% metakaolin by weight.

Although any type of clay is anticipated, a silicate material known as

Kaolin is preferred, for example, AS₂H₂.

Although any type of plastic is anticipated, including, but not limitedto, polystyrene, ABS, acrylic, fiberglass, latex powder, and vinylacetate; polystyrene is preferred.

Although any form of polystyrene is anticipated, it is preferred thatthe polystyrene be in the form of a fine powder, between 75 to 375 mesh,preferably between 350 and 375 mesh. One method of producing polystyreneis a fine powder of around 350 to 375 mesh is by dry freezing thepolystyrene, and pulverizing and/or grinding the polystyrene to anapproximately 350-375 mesh. In some embodiments, the polystyrene isrecycled polystyrene, such as from packing material.

When a 65 pound bag of pre-mixed cement mix of the present invention ismixed with aggregate and water, it produces, for example, a similaramount of product as a 78 or 80 pound bag of pre-mixed cement of theprior art. Therefore, less weight is transported to the job site, lessstrain is placed upon the workers, yet the same amount of resulting mixis derived. Equivalent and proportional results are achieved withsmaller or larger sized bags or containers.

Equivalent elements can be substituted for the ones set forth above suchthat they perform in substantially the same manner in substantially thesame way for achieving substantially the same result.

It is believed that the system and method of the present invention andmany of its attendant advantages will be understood by the foregoingdescription. It is also believed that it will be apparent that variouschanges may be made in the form, construction and arrangement of thecomponents thereof without departing from the scope and spirit of theinvention or without sacrificing all of its material advantages. Theform herein before described being merely exemplary and explanatoryembodiment thereof. It is the intention of the following claims toencompass and include such changes.

What is claimed is:
 1. A pre-mixed mortar, stucco or masonry compositioncomprising: 70 to 80 percent sand; and 20 to 30 percent light-weightcement mix composition comprising: either slag cement, Gypsum or acombination of slag cement and gypsum; Portland cement; silicon dioxide;calcium stearate; and metakaolin.
 2. The pre-mixed mortar, stucco ormasonry composition of claim 1, wherein the light-weight cement mixcomposition comprises from 1 to 10 percent silicon dioxide by weight. 3.The pre-mixed mortar, stucco or masonry composition of claim 1, whereinthe light-weight cement mix composition comprises from 0.5 to 2 percentcalcium stearate by weight.
 4. The pre-mixed mortar, stucco or masonrycomposition of claim 1, wherein the light-weight cement mix compositioncomprises from 1 to 10 percent metakaolin by weight.
 5. A pre-mixedmortar, stucco or masonry composition comprising: approximately 75%sand; and approximately 25% light-weight cement mix, the light weightcement mix comprising: 1 to 10 percent silicon dioxide; 0.5 to 2 percentcalcium stearate; 1 to 10 percent metakaolin; up to 20 percent slagcement; and 60 to 91 percent Portland cement.
 6. The pre-mixed mortar,stucco or masonry composition of claim 5, wherein mixing the contents ofthe 65 pound bag with water produces an equivalent amount of pre-mixedmortar, stucco or masonry composition as a standard 80 pound bagpre-mixed mortar, stucco or masonry composition.
 7. A pre-mixed mortar,stucco or masonry composition comprising: approximately 75% sand; andapproximately 25% light-weight cement mix, the light weight cement mixcomprising: 1 to 10 percent silicon dioxide; 0.5 to 1 percent calciumstearate; 1 to 10 percent metakaolin; up to 20 percent slag cement; andup to 91 percent Portland cement.
 8. The pre-mixed mortar, stucco ormasonry composition of claim 8, wherein the pre-mixed mortar, stucco ormasonry composition is provided in 65 pound bags.
 9. The pre-mixedmortar, stucco or masonry composition of claim 8, wherein mixing thecontents of the 65 pound bag with water produces an equivalent amount ofpre-mixed mortar, stucco or masonry composition as a standard 80 poundbag pre-mixed mortar, stucco or masonry composition.